INSTALLATION INSTRUCTIONS KAWASAKI MULE PRO-FXT

Transcription

1 INSTALLATION INSTRUCTIONS

2 SAFETY INSTRUCTIONS Warning: Failure to heed all safety and operating instructions and warnings regarding use of this product can result in serious bodily injury. READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS BEFORE STARTING OF ASSEMBLY Install all parts indicated in assembly instructions. Failure to fully assemble product before use could result in personal injury. Assembly of product requires use of hand or power tools. If you are not experienced in using these types of tools, have product dealer do the install for you. Some parts contain sharp edges, wear protective gloves if necessary. Always keep your assembly area clean, uncluttered and well lit. Keep visitors and children a safe distance away from the assembly area. Visitors should wear the same safety equipment described under. 2 Never operate your UTV with the cab doors open. Failure to properly latch the doors before moving the vehicle could result in serious injury. Dress for safety. DO NOT wear loose clothing, gloves, neckties or jewelry if using power tools to assemble this product. Insert all nut covers after you finish installation. Never drive your UTV with the cab front window in open position. Failure to properly latch/lock front window before driving the vehicle could result in serious injury. For safety purposes, if the DFK Cab doors are removed, it is mandatory that the OEM Half Doors or Nets are REINSTALLED before operating vehicle.

3 MAINTENANCE AND CLEANING To clean polycarbonate surface use soapy water solution or other subtle means. Dirt and dust wash by gently water stream and swipe only with wet or damp means in the direction from top to bottom. The recommended frequency of cleaning of polycarbonate part is about 1 time per month or according to the actual degree of pollution. Do not use detergents that could scratch the surface plates. (abrasives, harsh fabrics, etc.) Do not use solvents or alkaline detergents or cleaners with ammonia (ammonium hydroxide). Do not remove the impurities from the surface of the razor blades or other sharp items. Do not clean cabin when the polycarbonate plates are heated by the sun. 3 Do not use the squeegee, it could be scratched surface plates. Do not clean the water current strength greater than 50 bar (WAP) The manufacturer is not responsible for scratching the surface in case of failure to comply with the above instructions. All bolted connections of cab must be by user at regular intervals checked and tightened.

4 PREPARATION FOR INSTALLATION: Uninstall all additional systems from the roller cages (work lights, rear mirrors, drink holders etc.) CAB PREVIEW 4

5 RIGHT DOOR BASE + LEFT DOOR BASE One by one replace original screws (red circle) by including screws from inner side (next page). 5

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7 Place the right rear door base onto the UTV roller cage. 7

8 One by one replace the screws from the outter side and fix the right rear door base with the UTV roller cage. 8

9 Place the right rear door base holders onto the right rear door base and fix by included screws, washers, nuts and covers. 9

10 Repeat previous steps with the left rear door base. 10

11 One by one replace original screws (red circle) by included screws from inner side (next page). 11

12 12

13 Place the right front door base onto the UTV roller cage. 13

14 One by one replace the screws from the outter side and fix the right front door base with the UTV roller cage. 14

15 Place the right front door base holders onto the right front door base and fix by included screws, washers, nuts and covers. 15

16 Repeat previous steps with the left front door base. 16

17 REAR PANEL Stick the self glued rubber seal onto the rear UTV frame. Make sure that surface of the frame is clean. 17

18 Place the rear assembly onto the the seal. 18

19 Place the rear upper holder onto the rear polycarbonate and fix by included screw, washers, nut and cover. 19

20 Place the rear bottom holder onto the rear polycarbonate and fix by included screw, washers, nut and cover on both sides. 20

21 Place the rear side holders onto the rear polycarbonate and fix by included screws, washers, nuts and covers on both sides. 21

22 FRONT PANEL 1. One by one replace the original screws (red circle) by included screws from inner side (next page) on both sides. 22

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24 Place front bottom ledge onto the UTV roller cage. 24

25 One by one replace the screws from the outer side and fix the front bottom ledge with the UTV roller cage on both sides. 25

26 Insert the included front door stop holder screws into the front bottom ledge holder holes. 26

27 Place the front bottom ledge holder with the screws onto the front bottom ledge and fix by included screws, washers, nuts and covers on both sides. 27

28 Place the front upper ledge onto the UTV roller cage. 28

29 Place the front upper ledge side holder onto the front upper ledge and fix by included screw, washer, nut and cover on both sides. 29

30 ROOF Place the front roof panel onto the UTV roller cage. Take extra care if you have model with A/C pre-installed on the front roof panel. 30

31 Place the front upper ledge/roof holders onto the front upper ledge and fix by included screws, washers, nuts and covers. 31

32 Place the front roof holder ledge onto the front roof panel and fix by included screws, washers, nuts and covers. 32

33 Place the roof hinges onto the front roof panel and fix by included screws, nuts and covers. 33

34 Place the rear roof panel onto the UTV roller cage. 34

35 Adjust the rear roof panel into best position and fix the roof hinges with the rear roof panel by included screws, nuts and covers. 35

36 Place the rear roof holder onto the rear roof panel and fix by included screw, washer, nut and cover. 36

37 Install the roof gas spring into the roof gas spring holders and fix by included nut, washers, and cover. 37

38 ELECTROINSTALLATION WIPER SET View onto the wiper motor with the cover and with the middle ledge. 38 Place the washer onto the wiper longer pin.

39 Place the washer onto shorter wiper pin. View onto installed washers. 39

40 Place the wiper assembly onto the front glass from inner side. Insert these washers onto the wiper s pins and onto the glass from outer side. Fix the wiper motor with the front glass by included nuts and tighten these correctly. 40

41 FRONT PANEL 2 Place the front glass assembly onto the front upper ledge by hinges and fix by included screws, washers, nuts and covers. 41

42 Install the front gas spring into the front gas spring holders and fix by included nuts, wahers and covers. 42

43 RIGHT DOOR + LEFT DOOR Place the right rear door stop holder 2 onto the right rear door stop 1 and fix by included screws, washers, nuts and covers. Install the door stop assembly into the right rear door stop holder 1. 43

44 Place the right rear door stop assembly onto the right front door base in accordance with the welded nuts and fix by included screws and washers. 44

45 Place the right frame hinges onto the right rear door base and fix by included screws, washers, nuts and covers. Lubricate the hinges pins and place washers 10 onto the pins. 45

46 Do NOT switch the upper and bottom hinge. 46

47 Place the right rear door onto the hinges. 47

48 Adjust the right rear door into the best position and tighten screws correctly. 48

49 Adjust the right rear door stop assembly into the best position and tighten screws correctly. 49

50 Install the door gas spring into the right rear gas spring holders and fix by included nuts, washers and covers. 50

51 Place the right frame hinges onto the right front door base and fix by included screws, washers, nuts and covers. Lubricate the hinges pins and place the washers 10 onto the pins. 51

52 Install the gas spring assembly into the right front door stop holder. 52

53 Place the right front door stop assembly onto the front bottom ledge holder prepared screws and fix by included nuts, washers and covers. 53

54 Place the front door ledge onto the original door hinges and fix the ledge with the hinges by included screws, washers, nuts and covers. Fix the front door ledge with the front dashboard by included rubber rivet. 54

55 Place the right front door onto the hinges. 55

56 Adjust the right front door into the best position by hinges and tighten screws correctly. 56

57 Adjust the right front door stop assembly into the best position and tighten screws correctly. 57

58 Install the door gas spring into the right front gas spring holders and fix by included nuts, washers and covers. 58

59 Place the right door mirror onto the right mirror holder and fix by included screws, washers, nuts and covers. 59

60 Place the right door mirror assembly onto the right front door and fix by included screws and washers. 60

61 Repeat previous steps with the left doors. 61

62 Place the rear frame lock cover holder onto the rear panel lock cover and fix by included swell action latch. 62

63 Place the rear panel lock cover assembly into the best position and fix with the UTV panel by included rubber rivets. 63

64 Place the fuel tank cover into the best position and fix by included rubber rivets. 64

65 ELECTROINSTALLATION WIPER/WASHER ASSEMBLY Overall wiring diagram (wiper/washer) 65 SEE NEXT PAGES

66 Washer tube Parts needed (Included) Switch wiper/washer/off Harness and washer tank 66

67 Install the washer tank to the UTV by washer tank holder and correct screw, washers and nut (included). Run the harness branch No.: 2 from the harness to the dasboard inner space (blue line). 67

68 Find the best place for wiper/washer switch and cut rectangle hole for that. Connect the harness branch No.: 2 with the swith and insert that into the hole. Run the harness branch No.:1 around the roller cage to the wiper motor. 68

69 Connect the harness branch No.:1 with the wiper motor and stretch the washer hose through the bushing. Run the harness branch No.: 4 from the harness to the UTV s main electrification. Find the original cable where is 12V+ after you turn on the main UTV s switch. Connect the harness cables, red to 12V+original electrification and black to UTV s skelet. 69 If you don t find connection for connectors installed on harness branch, you can use other connectors (included). Fill the washer liquide into the washer tank before first usage.

70 Now you can turn on wiper switch and look on the larger wiper pin. If you connect all harness connectors correctly, pin is turning. Find the ends of turning and install the wiper arm on correct position. Fix the wiper arm with the wiper motor pin by included nut. Insert plastic holder onto the wiper latch pin in correct position 70

71 View onto the installed plasstic holder. Insert the wiper arm hook onto the wiper latch plastic holder and press it into the correct position. 71

72 View onto installed wiper arm hook. Connect the washer hose from the harness with the washer hose from wiper arm by included tube. 72

73 ELECTROINSTALLATION HEATER Overall wiring diagram (heater) 73

74 IMPORTANT IT IS ABSOLUTELY NECESSARY TO TAKE OUT THE RUBBER PLUGS FROM THE HEATER TUBES!!! 74

75 Drill necessary holes into the rear glove box cover and lead the hot water hoses and the heater harness through(red circles). 75 Install the hot water pump onto the hot water hose(red circle). Take extra care to the correct orientation. Connect the hot water pump to the pump harness.

76 Install the heater holder to best position (heater assembly covers the golve box) and fix these with the UTV s body by included rubber rivets. 76

77 Run the harness branch from the harness to the UTV s main electrification. Find the original cable where is 12V+ after you turn on the main UTV s switch. Connect the harness cables, red to 12V+original electrification and black to UTV s skelet. If you don t find connection for connectors installed on harness branch, you can use other connectors (included). 77

78 Connect hot water hose with the UTV s cooling circuit near the cooler by Y coupling (included). Lead the second hot water hose under the UTV floor to the engine. 78

79 Connect hot water hose with the UTV s cooling circuit near the engine by Y coupling (included). Connect the heater to the hot water hoses and to the heater harness and place the heater onto the heater holder and fix by included nuts, washers and covers on both sides. 79

80 It is absolutely necessary to bleed the air out of the UTV s engine cooling system. Incomplete bleeding of cooling system can result in engine damage. If you don t have sufficient experience with this process, we strongly recommend professional service technician assistance. We are not responsible for damages when cooling system bleeded incompletely. Please note that aditionall heater system will absorbed more than 2 liters of coolant fluid. 1. Important: After the heater system installed check the system for leaks. Turn on the electric vent switch and confirm that the engine is cold. Start the engine, open bleeding valve and wait untill engine warmes up. Important: Allways check engine temperature if it overheats turn of engine. 2. To achieve engine operating temperature depress the accelerator to increase The engine RPM. This will increase the preasure and flow of the water pump forcing more coolant through the heater. After operating temperature ceache turn of engine and open it. Trapped air should come out from heater system throughout bleeding valve. Repeat this procedure until heater/cooling system is completely bleeded out. The DFK Cab heater, like the heater in a car, generates heat from the vehicle s engine. In nearly all cases, the heater should generate enough heat from your UTV, side by side, or tractor engine that you may need to turn the heater off periodically otherwise the air in the cabin may be too hot. 80 It is important to check the coolant level regularly at least 4-5 times during the first several days of operation and fill as necessary until the coolant level has stabilized. The heater will draw and retain coolant, sometimes at the expense of coolant to the engine. This can cause engine overheating if not managed properly.